Methods for producing a soccer ball

ABSTRACT

A sports ball having a high-performance cover formed from a plurality of embossed panels. The panels embossed at 2-3 mm from the edges of each of the panels. High tension stitching applied at the embossed regions for formulating a high performance soccer ball.

TECHNICAL FIELD

The present disclosure relates generally to a ball and a method formanufacturing a ball. More particularly, and without limitation, thepresent disclosure relates to structures and methods for manufacturing asports ball.

BACKGROUND

Conventional hand stitched and thermo bonded soccer balls have numerousdrawbacks related to costs and performance. For example, the labor forhand-stitching balls is expensive since manufacturing a hand-stitchedsoccer ball may take two to four days. These balls also use a largeamount of materials including three or more layers of cloth and a largeamount of latex adhesive. Additionally, in hand stitched balls, thestitches are exposed on the surface of the ball. The exposure of thestitches on the surface leads to quicker abrasion of a manufacturedball.

On the other hand, thermo bonded soccer balls do not contain stitchesthat may be exposed on the outer surface, thermo bonded soccer ballshave high transportation costs associated with them since they may notbe deflated. For example, 7,500 deflated soccer balls may be packed in atwenty foot container, while only 2,500-3,000 thermo bonded soccer ballsmay be transported in the same container-leading to significantly highertransportation costs. Exemplary embodiments, consistent with the presentdisclosure, therefore aim to resolve the aforementioned problems, amongothers.

SUMMARY

An object of the invention is to provide a new and improved soccer ballhaving a high performance, robust shape, and durability. In an exemplaryembodiment, a soccer ball includes a bladder and a plurality of panelsstitched together at stitch lines at an embossed portion of each of theplurality of panels, the stitch lines 2-3 mm from respective edges ofeach of the plurality of panels.

In an exemplary embodiment, a manufacturing method of a soccer ball isprovided. Exemplary methods include cutting out a plurality of panelsfrom a sheet of padding, determining stitch lines for each of theplurality of panels, applying heat and pressure at the stitch lines forembossing the plurality of panels. The method further includes creatinga bladder valve panel by inserting a valve attached to a bladder in themiddle of one of the plurality of panels, stitching at least a few ofthe plurality of panels using machine stitching at the stitch lines,inverting the soccer ball inside out so that the bladder is containedwithin the soccer ball, hand stitching any remaining unstitched stitchlines, and inserting air in the bladder and molding the soccer ball byapplying heat and external pressure to the soccer ball and internalpressure due to the air in the soccer ball.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate exemplary embodiments of thepresent disclosure and, together with the description, serve to explainthe principles of the disclosure.

FIGS. 1-3 show cross-section of exemplary paddings used for covers of asoccer ball, consistent with exemplary embodiments of the presentdisclosure;

FIGS. 4A and 4B are illustrations of an exemplary scenario for cuttingout panel shapes, consistent with exemplary embodiments of the presentdisclosure;

FIGS. 5A-C illustrate an exemplary scenario for stitching two panelstogether, consistent with exemplary embodiments of the presentdisclosure;

FIGS. 6A-C are different views of a panel, consistent with exemplaryembodiments of the present disclosure;

FIGS. 7A-7J illustrate various shapes of panels, consistent withexemplary embodiments of the present disclosure;

FIG. 8 illustrates an exemplary step for creating a bladder valve panel,consistent with exemplary embodiments of the present disclosure;

FIGS. 9A and 9B illustrate exemplary bladders, consistent with exemplaryembodiments of the present disclosure;

FIGS. 10A and 10B illustrate exemplary bladders attached to respectivebladder valve panels, consistent with exemplary embodiments of thepresent disclosure; and

FIGS. 11A-C illustrate some exemplary steps for stitching panels of asoccer ball, consistent with exemplary embodiments of the presentdisclosure.

DETAILED DESCRIPTION

A soccer ball is made up of two major components, a bladder and a coverof panels. Embodiments consistent with the present disclosure enhancethe performance of a soccer ball by providing a method and structure forefficient stitching of panels. Specifically, exemplary embodimentsprovide for determining stitch lines where panels may be stitchedtogether. Embossing or applying of heat and pressure may be used tocreate a depression or cavity for applying the stitching at the stitchlines. Therefore, embossing may allow for panels to be tightly stitchedtogether providing a smooth surface exterior surface in a soccer ballwhere stitches may have minimal external exposure. When an air bladderincluded within a soccer ball is filled with air and a molding deviceapplies pressure and heat on the outside surface, a soccer ball may bemanufactured with uniformity and consistency in shape. Accordingly,soccer balls that are manufactured by using exemplary methods may havebetter performance and outer appearance than hand-stitched and thermobonded balls.

FIG. 1 shows a cross-section of materials comprising padding 100 forpanels of a soccer ball, consistent with exemplary embodiments of thepresent disclosure. Padding 100 may include an outer material sheet 102which may be a layer of Polyvinyl Chloride (PVC), Polyurethane (PU), ora similar synthetic material. Outer material sheet 102 may be laminatedto a first layer of ethylene propylene diene monomer (EPDM) compoundfoam 106. The lamination may be completed using an adhesive 104, such asa latex adhesive. Padding 100 may further consist of rubber sheet 110,adhesive 112, EPDM foam 114, adhesive 116, and a thin layer of cloth orfabric 110. Adhesives 112 and 114 may be a latex adhesive. Furthermore,rubber sheet 110 may consist of natural rubber or latex sheet orsynthetic rubber. In embodiments, outer material sheet 102 may have athickness of 0.3-1.8 mm, foam 106 may have a thickness of 2-3 mm, EPDMfoam 114 may have a thickness of 2 mm-3 mm rubber sheet 110 may have athickness of 0.5-1.5 mm. In embodiments, total thickness of padding 100may be 2-9 mm. In embodiments, padding 100 may be heated and dried for apre-determined period. For example, padding 100 may be dried at 55degrees Celsius for up to one hour or more.

FIG. 2 shows a cross-section of materials comprising another padding 200for panels of a soccer ball, consistent with exemplary embodiments ofthe present disclosure. Padding 200 may include an outer material sheet202, similar to outer material sheet 102. Outer material sheet 102 maybe laminated along with rubber sheet 206, EPDM foam 210, and fabric 214using adhesives 204, 208, and 212, such as latex adhesives. Inembodiments, rubber sheet 206, EPDM foam 210, and fabric 214 arerespectively of the same materials as rubber sheet 110, EPDM foam106/114, and fabric 118. However, in padding 200, outer material sheet202 may have a thickness of 0.3-1.8 mm rubber sheet 306 may have athickness of 0.5-1.5 mm, EPDM foam 210 may have a thickness of 2-4 mmand fabric 214 may have a thickness of 0.5-1.5 mm. In embodiments, totalthickness of padding 200 may be 2-9 mm. In embodiments, padding 200 maybe heated and dried for a pre-determined period. For example, padding200 may be dried at 55 degrees Celsius for up to one hour or more.

FIG. 3 shows a cross-section of materials comprising another padding 300for panels of a soccer ball, consistent with exemplary embodiments ofthe present disclosure. Padding 300 may include an outer material sheet302, similar to outer material sheets 102 and 202 0.3-1.8 mm. Outermaterial sheet 302 may be laminated along with rubber sheet 306, EPDMfoam 310, and fabric 214 using adhesives 304, 308, and 312, such aslatex adhesives. In embodiments, rubber sheet 306, EPDM foam 310, andfabric 314 are respectively of the same materials as rubber sheet 110,EPDM foam 106/114, and fabric 118. However, in padding 300, outermaterial sheet 302 may have a thickness of 0.3-1.8 mm, rubber sheet 306may have a thickness of 0.5-1.5 mm, EPDM foam 210 may have a thicknessof 4-6 mm, and fabric 314 may have a thickness of 0.5-1 mm. Inembodiments, total thickness of padding 300 may be 2-9 mm. Inembodiments, padding 300 may be heated and dried for a pre-determinedperiod. For example, padding 300 may be dried at 55 degrees Celsius forup to one hour or more.

In embodiments, using various thicknesses of foams and variations in theorder of materials in the padding may lead to different properties for amanufactured soccer ball. For example, a ball's bounce, softness, orhardness may be impacted. These properties may impact a ball's reboundand/or touch characteristics.

FIGS. 4A and 4B are illustrations of an exemplary scenario for cuttingout panel shapes, according to an embodiment of the present disclosure.Layer 400 may represent either paddings 100, 200, or 300. As shown inFIG. 4A, required panel shapes (404, 406, and 408) may be cut from layer400 using conventional ball cutting knives. FIG. 4B illustrates anexemplary cutout 410 that may be cut from layer 400. Cutout 410 ishexagon shaped cutout of padding 400 to form a hexagon shaped panel.

FIG. 5A-5C are cross-sections of exemplary steps in the forming ofpanels of a soccer ball, consistent with embodiments of the presentdisclosure. One of ordinary skill in the art will comprehend, that theelements illustrated within FIGS. 5A-C are not drawn to scale. Instead,they have been illustrated in sizes that allow for easier comprehension.Additionally, while FIGS. 5A-5C show exemplary steps based on padding100, similar steps may be applied to padding 200, 300, or any othersuitable material that may be used for panels of a sports ball.

FIG. 5A illustrates two cutouts 502 and 504. In an exemplary embodiment,cutouts 502 and 504 may be cutouts from padding 100. As a first step,stitch lines 510, 512, 514, and 516 are determined. In an exemplaryembodiment, stitch lines may be a pre-determined distance from the edgesof the panels. One of ordinary skill in the art will comprehend that thedistance of stitch lines 510, 512, 514, and 516 from the edges ofcutouts 502 and 504 are not illustrated to scale but rather areillustrated relatively bigger for ease of understanding. Exemplarystitch lines 510, 512, 514, and 516 may be 2-3 mm from respective edgesof cutouts 502 and 504. In additional embodiments, distance of stitchlines from the edges may be determined based on thickness of thepadding. Each cutout of padding 100 may contain stitch lines where thevarious cutouts may be stitched to additional cutouts. Further detailsregarding stitch lines is provided further below accompanying thedescription of FIGS. 6A-C.

Accordingly, once stitch lines 510, 512, 514, and 516 are determined,heat and pressure from a source may be applied focusing on locations ofstitch lines 510, 512, 514, and 516. In an exemplary embodiment, 65-95degrees Celsius may be applied for up to 40-60 seconds. Therefore, anembossing machine (or any other source) may apply pressure and heat tostitching lines 510, 512, 514, and 516. In embodiments, an embossingmachine or any device with heated plates may be used for creatingchannels or stitch regions, that is, depressions or cavities.

FIG. 5B illustrates stitch regions 540, 542, 544, and 546 that arecreated by application of heat and pressure at locations correspondingto stitch lines 510, 412, 514, and 516. Stitch regions may represent acavity or depression created by the application of pressure and heat torespective cutouts 502 and 504. Specifically, within each stitch regions540, 542, 544, and 546, at location corresponding with stitch lines 510,412, 514, and 516, cutouts 502 and 504 have the minimal amount ofthickness. Furthermore, due to embossing, the edges of cutouts 502 and504 are turned up.

Accordingly, exemplary cutouts 502 and 504 are embossed due to moldingunder heat and pressure of the materials from the cutout of padding 100and the application of the pressure. Thickness of panels 502 and 504 isreduced in stitching regions 540, 542, 544, and 546. Once cutouts 502and 504 are cooled in this condition, they retain their shape with adepression or cavity in stitching regions 540, 542, 544, and 546.

FIG. 5C illustrates stitching 520 that is applied for stitching togethercutouts 502 and 504. Stitching 520 may be applied to all stitch lines ofa cutout for a first panel with cutouts for various other panels. Forexample, a hexagonal shaped cutout may be stitched together with sixother cutouts, each of the six cutouts forming parts of six respectivepanels of a soccer ball. In embodiments, stitching material may bepolyester or polyester cotton mix high strength thread applied by astitching machine, such as a high tension stitching machine. A hightension stitching machine may apply very high tension on a threadenabling the stitches to be invisible on the outer shell of amanufactured soccer ball.

In embodiments, an aspect of the step illustrated in FIG. 5C is thatstitching 520 is applied at respective stitch lines 512 and 514 withrespective surfaces of outer material 102 of cutouts 502 and 504 beingin contact with each other. Accordingly, after all panels are stitchedtogether, any machine stitching may be contained within a soccer ball.Additionally, fabric layers (fabric 118) may also be contained withinthe ball, as is apparent by the additional description provided in thedisclosure.

FIG. 6A-6C are different views of an embossed panel, according to anembodiment of the present disclosure. Exemplary panel 600 illustrates asingular panel as it may appear after the steps illustrated in FIGS.6A-C have been applied to any cutout of paddings 100, 200, or 300. Anaspect illustrated in FIGS. 6A-C is the difference in thickness atstitch lines as opposed to other regions of panel 600. For example, FIG.6A illustrates a top view of panel 600 that includes stitch region 624,stitch line 626, top surface 604, and edge section 622. In embodiments,top surface 604 may refer to a part of the panel where no pressure orheating is applied for embossing, that is, top surface 604 has athickness that is the same as the thickness of a respective cutoutbefore embossing. Stitch line 626 may represent location of where panel600 is stitched and where the pressure and/or heat is directly appliedby an embossing machine or a similar device. Stitch region 624 may referto all of the region where a cavity or depression may be created by theembossing process. Edge section 622 may represent a region where due toembossing, the edges may be turned up and/or thickness of the materialsis reduced.

As illustrated in a cross-section of panel 600 illustrated in FIG. 6B, adepth 621 of Stitch region 624 may be more than half a thickness 620 ofpanel 600 at top surface 604. Accordingly, panel 600 may have a minimumthickness at allocation of stitch line 626. In exemplary embodiments,before embossing, a distance between determined stitch line 626 andrespective edges of a cutout for panel 600 may be 2-3 mm.

FIG. 6C, illustrates a three-dimensional view of panel 600. Inembodiments, the three-dimensional view of panel 600 provides a furtherperspective indicating the location of stitch line 626 within stitchregion 624.

FIGS. 7A-7J illustrate various shapes of panels, consistent withexemplary embodiments of the present disclosure. FIG. 7A illustratespentagon-shaped panel 700 comprising stitch region 702, stitch line 704,top surface 706, and edge section 708. Similarly, FIGS. 7B-7J,illustrate different shaped panels 710, 720, 730, 740, 750, 760, 770,780, and 790, that each include respective stitch regions 712, 722, 732,742, 752, 762, 772, 782, and 792, corresponding stitch lines 714, 6 724,734, 744, 754, 764, 774, 784, and 794, top surfaces 716, 726, 736, 746,756, 766, 776, 786, and 796, and edge sections 718, 728, 738, 748, 758,768, 778, and 798. In embodiments, different shaped panels may bestitched to each other. For example, round-shaped panel 750 may bestitched panel 740.

FIG. 8 provides a cross-section of an exemplary bladder valve panel tofurther explain how the bladder valve panel is created, consistent withexemplary embodiments of the present disclosure. For example, a cavityor hole may be created in the middle of panel 502 through which valve810 may be passed through. Furthermore, an adhesive 802, such as a latexadhesive, may be applied between bladder flap 804 and fabric layer 118attaching bladder flap 804 to panel 502 creating an exemplary bladdervalve panel. As explained in further detail along with the explanationof FIGS. 9A and 9B, bladder flap 804 may refer to a portion of anexemplary bladder that may be attached to a bladder valve panel.Adhesive 802 may be applied between bladder flap 804 and fabric layer118 attaching bladder flap 802 to the bladder valve panel.

FIGS. 9A and 9B illustrate two exemplary bladders 900 and 902,consistent with exemplary embodiments of the present disclosure.Bladders 900 and 902 are both attached to exemplary valve 810. Inembodiments, adhesive may be applied to portions of bladders 900 and 902(bladder flap 804) surrounding valve 810 so that bladders 900 and 902may be permanently attached to a bladder valve panel. Bladder 900 may beany molded rubber or butyl or synthetic rubber that may be wound withpolyester or nylon threads. Bladder 902 may be a molded rubber or butylbladder or synthetic rubber that may be laminated with polyester orpolyester cotton cloth strips. In embodiments, additional bladders, withrestricted circumference properties may be used. In exemplaryembodiments, valve 810 may be used for inflating or deflating bladders900 and 902. Exemplary bladders aid in providing firmness and roundnessto a soccer ball. FIGS. 10A and 10B illustrate the two exemplarybladders 900 and 902, attached to exemplary bladder valve panel 1002.Bladder valve panel 1002 may be stitched together with additional panelsformed using the method illustrated in 5A-C to form a soccer ball.

In exemplary embodiments, most of the panels are machine-stitchedtogether, with the fabric layers 118 being exposed on the outside of thesoccer ball when machine stitching is being applied. Then, the ball maybe inverted inside out, where the bladder is contained within the soccerball. Hand stitching may then be applied to any remaining un-stitchedpanel edges. In embodiments, only an amount of panels edges are left forhand stitching that are needed to invert a soccer ball inside out sothat the bladder is contained within the stitched-together panels. Inembodiments, a length of panel edges where hand-stitching may be appliedis four to six inches.

FIGS. 11A-C illustrate some exemplary steps for stitching panels of asoccer ball, consistent with exemplary embodiments of the presentdisclosure. FIG. 11A illustrates soccer ball 1100 with various panels.Numerous panels and/or panel edges of soccer ball 1200 are stitchedtogether using machine stitching 1112 as discussed above with respect toFIGS. 5A-C. A cavity 1102 exposing bladder 902 may to be hand-stitchedusing string 1104. FIG. 11B illustrates a second stage of hand stitchingwhere panels are pulled closer together and string 1104 may be beingapplied at exemplary position 1106. FIG. 11C illustrates a completedstitched soccer ball 1100 with majority of the panels and/or panel edgesbeing stitched together by applying machine stitching 1112. Four paneledges are stitched together using hand stitching 1210.

In embodiments, once the machine and hand stitching is complete, abladder contained within a soccer ball may be completely filled withair. Then, the soccer ball may be placed in a heated molding machinewhich is round in the finalized shape of a soccer ball. Heating underpressure of the inner cover of the molding machine may then be appliedto the soccer ball for providing a permanent shape to the soccer ball.In some embodiments, the soccer ball may be molded at 70 degrees Celsiusfor thirty seconds to sixty seconds. Accordingly, a total of sixtysecond of heat of 70 degrees Celsius may be applied to the soccer ball.In embodiments, because of foam material included within padding, whenheat and pressure are applied during molding, exemplary stitch regions,that is, cavities or depression are filled. Accordingly, the materialsincluded within the padding extending to the stitching filing thecavities and providing the cover a robust round shape. Therefore, theball sets uniformly from inside due to pressure by the bladder and fromoutside due to the pressure and/or heat applied by the mold.

In embodiments, any seams in a ball may be sealed by application ofsealants before or after molding. Exemplary sealants may includepolyurethane liquids among others.

In embodiments, exemplary soccer balls manufactured according toexemplary methods aid in reducing manufacturing costs significantly,while at the same time, the ball rebounds, has waterresistance/absorption, and has abrasion properties that are superior tothe characteristics of current hand stitched and thermo bonded balls.Furthermore, the ability to transport these balls while they aredeflated also leads to numerous commercial advantages such assignificant reduction of cost compared to transportation of thermobonded balls.

In some embodiments, the exemplary methods of stitching togetherembossed panels may be applied in any types of balls that utilize panelsand bladders, such as footballs, rugby balls, volleyballs, water poloballs, etc.

What is claimed:
 1. A manufacturing method of a soccer ball, comprisingthe steps of: a. cutting out a plurality of panels from a sheet ofpadding; b. determining stitch lines for each of the plurality ofpanels; c. applying heat and pressure at the stitch lines for embossingthe plurality of panels creating respective channels; d. creating abladder valve panel by inserting a valve attached to a bladder in themiddle of one of the plurality of panels; e. stitching at least a few ofthe plurality of panels using machine stitching at the stitch lines; f.inverting the soccer ball inside out so that the bladder is containedwithin the soccer ball; g. hand stitching any remaining unstitchedstitch lines; and h. inserting air in the bladder and molding the soccerball by applying heat and external pressure to the soccer ball andinternal pressure due to the air in the soccer ball.
 2. The method ofclaim 1, wherein creating respective channels comprises creatingdepressions at the stitch lines.
 3. The method of claim 1, whereinmolding the soccer ball by applying heat and external pressure to thesoccer ball and internal pressure due to the air in the soccer ballcomprises molding the soccer ball until ethylene propylene diene monomer(EPDM) foam included within the padding expands to fill the respectivechannels.
 4. The method of claim 1, wherein the stitch lines are 2-3 mmfrom respective edges of the plurality of panels.
 5. The method of claim1, applying heat and pressure at the stitch lines for embossing theplurality of panels creating respective channels comprises applying heatand pressure using heated plates.
 6. The method of claim 1, wherein thesheet of padding consists of ethylene propylene diene monomer (EPDM)foam, adhesives, and fabric.
 7. The method of claim 1, wherein surfacesof all the panels in contact with the bladder are fabric.
 8. The methodof claim 1, wherein the hand stitching is applied for four to sixinches.
 9. The method of claim 1, wherein the soccer ball comprises ofthirty-six panels.
 10. The method of claim 1, wherein a maximumthickness of each of the plurality of panels is 6-9 mm and a stitchregion thickness at the stitch lines is 2-3 mm.
 11. A manufacturingmethod of a soccer ball, comprising the steps of: a. cutting out aplurality of panels from a sheet of padding; b. determining stitch linesfor each of the plurality of panels; c. applying heat and pressure atthe stitch lines for embossing the plurality of panels creatingrespective channels; d. creating a bladder valve panel by inserting avalve attached to a bladder in the middle of one of the plurality ofpanels; e. stitching at least a few of the plurality of panels usingmachine stitching at the stitch lines; f. inverting the soccer ballinside out so that the bladder is contained within the soccer ball; g.hand stitching any remaining unstitched stitch lines; h. inserting airin the bladder; and i. molding the soccer ball by applying heat andexternal pressure to the soccer ball and internal pressure due to theair in the soccer ball until ethylene propylene diene monomer (EPDM)foam included within the sheet of padding expands to fill the respectivechannels.